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Pelican Technical Article:

Porsche Boxster 996 Engine Swap
Page 18

Difficulty Level: 9
Difficulty scale: Adding air to your tires is level one
Rebuilding a Porsche Motor is level ten

  This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster.  The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads.   With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details. 
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Figure 1
   Here's another shot of the engine showing that 996 side bracket that must be removed by loosening up both the plastic and aluminum intake manifolds.
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Figure 2
   Here's a photo with the bracket finally removed.
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Figure 3
   The electrical connections for the starter need to be relocated (more on this later).  Start by disconnecting the bracket from the intake manifold.
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Figure 4
      Unplug the line from the air-oil separator.  Squeeze the ends of the lines and then pull them off.  We will be using our own custom line, so place this one aside, as we will no longer need it.
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Figure 5
   This is a small coolant line that is used to warm the air-oil separator on the 996.  I'm not quite sure why (and I've asked many experts), but the Boxster does not have the coolant hose connections for the air-oil separator unit that the 996 does.  Remove this line, as we will not be using any coolant lines with our Boxster conversion air-oil separator.  Supposedly the coolant lines are used to warm the unit in very cold weather.
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Figure 6
   Now remove the small plastic bracket that holds that small coolant line.
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Figure 7
   Pull off the line.
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Figure 8
   Pull back the bundle that is attached to the air-oil separator unit.  Put this bundle aside, as the manifold is ready to be removed.
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Figure 9
   I took this series of photos as I lifted up the intake manifold.  If you don't know where everything goes underneath, you will be confused when you're ready to put everything back together.  Refer to this photo and the following ones for the proper routing of the small vacuum hoses.
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Figure 10
   Vacuum hose routing.
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Figure 11
   Vacuum hose routing.
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Figure 12
   Vacuum hose routing.
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Figure 13
   Vacuum hose routing on the opposite side.
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Figure 14
   Here's the top of the engine with the intake manifold (plastic part) removed.
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Figure 15
   Top shot with manifold removed.
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Figure 16
   Here's another angle.  The starter is on the left, the alternator is at the top of the photo.
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Figure 17
   Top shot with manifold removed - looking down directly at the starter.
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Figure 18
   Top shot with manifold removed - this photo shows more of the opposite side, near the oil cooler.
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Figure 19
   Close-up view of the air-oil separator with the hoses attached.
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Figure 20
   Close-up shot of the starter and it's connections.
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Figure 21
   Photo from opposite side with manifold removed.
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Figure 22
   This hard plastic line goes from the air-oil separator to the camshaft housing area.  This line stays in place.
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Figure 23
   Another shot of that air-oil separator line.
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Figure 24
   In this photo, you can see the air-oil separator line, the power steering supply hose, the main electrical harness for the starter, and the engine wire harness.
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Figure 25
   Another shot from the flywheel side.
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Figure 26
   I took a lot of photos at this point because I knew I would be referring back to them later when it came time for reassembly.
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Figure 27
   Close-up of the starter motor.
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Figure 28
   This contraption is a valve for the air pump, and a vacuum canister that acts as a vacuum capacitor / reservoir.
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Figure 29
   The bendable hose in this photo is the oil filler tube, which we will remove shortly.
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Figure 30
   Here's a close-up of the power steering reservoir, which is easily damaged when you remove the line (more on this later).
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Figure 31
   Here's the 996 oil cooler, which we will replace with a Boxster cooler.  Even though the 996 one will fit in the Boxster, the air intake tube typically runs through this area, and you might have difficulty fitting your intake into place if you retain the full-height 996 cooler.
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Figure 32
   Photo of the engine from the back corner.
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Figure 33
   Another shot of the rear of the power steering reservoir.
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Figure 34
   In the center here is the oil dipstick, which we will be removing shortly as well.
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Figure 35
   Here's a close-up photo of the vacuum tee.  Refer to these photos for clarity when you're reassembling the engine.
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